SPE 92361

Using a Flexible, Expandable Sealant System to Prevent Microannulus Formation

in a Gas Well: A Case History
H. El-Hassan, M. Sultan, and A.A. Saeed, ADCO, and C. Johnson, SPE, A. Belmahi, and L. Rishmani, Schlumberger

Copyright 2005, Society of Petroleum Engineers Inc.

This paper was prepared for presentation at the 14th SPE Middle East Oil & Gas Show and
Conference held in Bahrain International Exhibition Centre, Bahrain, 1215 March 2005.
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presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
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Abstract
Long-term zonal isolation of gas reservoirs is a difficult
problem. This paper summarizes the implementation and
evaluation of a new sealant system designed to overcome this
problem by preventing formation of a microannulus across the
gas zone. A case history of its use in a well in the United Arab
Emirates demonstrates the successful application of the
flexible, expandable sealant material to prevent microannulus
and maintain cement sheath integrity in the production casing
section.
In one well, a conventional cement slurry formulation was
used for the 9 5/8-in. section. The section was then tested to
3,000 psi pressure. Cement-bond logs showed clear
deterioration of cement sheath quality behind the casing. A
similar result for upcoming casing sections was a concern, so
the sealant was redesigned to accommodate downhole stresses
across the interval. The new design, which was used in the 7in. liner section in the same well, enabled mechanical and
expansion properties to be engineered to withstand downhole
stresses and minimize the debonding effect. After successful
isolation in the first well, the flexible, expandable sealant
material was established as standard practice in similar wells.
Introduction
A major operator in the United Arab Emirates faced the
problem of sustained annular pressure (SAP) in some fields.
This problem, when attributed to sealant behind the casing, is
mainly the result of the failure of this sealant to provide
adequate zonal isolation. Sealant failure is usually not related
to its placement during the well construction phase but to
failure during the production life of the well. According to
several studies,1,2,3,4 changes in downhole conditions lead to
mechanical damage of the set cement behind the casing that

can cause either direct mechanical failure of the system or the

creation of microannuli. Many factors can cause these changes
in wellbore pressure, wellbore temperature, or formation
loading.
Bulk shrinkage of ordinary Portland cement can also create
flow paths for wellbore fluids. A change in the external
volume of the system is a result of hydration of the cement
during the setting phase and is a function of the percentage of
the four major clinker minerals and consequently the cement
class.
Case HistoryBackground. This zonal-isolation problem
was encountered when a high-profile well was drilled. The
objective was to appraise oil- and gas-bearing formations and
complete the well as a single horizontal gas producer. The
design included 9 5/8-in. casing followed by a 7-in.
production liner and a 6-in. horizontal openhole section.
The 9 5/8-in. section was cemented with conventional
slurry designed for current downhole conditions. The slurry
weight was 16.7 ppg with a compressive strength of 4,000 psi.
A cement-bond log indicated good sealant properties behind
the casing. After logging, the section was subjected to a 3,500psi pressure test.. A second cement-bond log indicated clear
deterioration and failure to withstand the pressure (refer to
Fig. 1 and Fig. 2 for relevant log sections).
Numerical Stress Modeling
A mathematical simulator based on thermo-elastic models was
used to analyze the 9 5/8-in. section. This stress analysis
software performs two-dimensional stress and temperature
calculations to predict formation of a microannulus or cement
failure in tension or compression. The model considers steel,
cement, and rock as thermo-elastic materials. It also considers
that the steel/cement interface and the cement/rock interface
are either fully bounded or not bounded. Finally, the simulator
assumes that the cement is under no internal stress after
setting. Only variations of pressure and temperature, which
occur once the cement is set, are considered. Thiercelin et al.1
present a detailed description of the model assumptions.
Pressure-testing conditions in the 9 5/8-in. section were
simulated in the stress analysis software. A Youngs modulus
of 1,700,000 psi and a Poissons ratio of 0.19 were used. The
data input were actual values imported from the job design.
The simulation predicted failure in traction of the conventional

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Using a Flexible, Expandable Sealant System to Prevent Microannulus in a Gas Well A Case History

slurry. With 4,000 psi compressive strength and an increase of

3,500 psi for pressure testing, the stress generated exceeded
the tensile strength of the system by 153%. This caused the
loss of cement integrity. (Refer to Fig. 3 for software input
and output windows.) Following recommendations from the
stress analysis software, the required Youngs modulus
required to withstand applied stresses was less than or equal to
1,213,757 psi, a large difference from 1,700,000 psi of the
system currently in use.
Flexible, Expandable Sealant System
To address the issue of failed cement sheaths and tailor
mechanical properties of a set-cement system, a new type of
flexible and expandable sealant system technology has been
proposed. Based on the optimized, tri-modal, particlecomposition theory, 5 it encompasses all the advantages of an
engineered particle-size distribution blend and the additional
benefits of specific particles that can adjust the flexible
properties and expansion capabilities of set cement.
During the production life of a well, the cement sheath is
exposed to varying stress fields as pressure and temperature
fluctuate in the wellbore. These stresses can compromise the
integrity of the cement sheath and affect its ability to maintain
hydraulic isolation. Studies have shown that cement with a
low Youngs modulus and good expansion properties during
the hardening phase is best for mechanical durability and
resistance to stresses.2,5
This system is adaptable to pressure and temperature
changes, and the ability to expand improves sealing at the
casing/formation interface.6 The addition of flexible material
to the optimized blend plays an important role in increasing
the flexibility of set cement by decreasing the Youngs
modulus.
The system applications focus on the need for zonal
isolation in wells with severe changes in downhole
temperature and pressure, gas wells, high-pressure and hightemperature (HPHT) wells, plug-and abandon-applications,
multilateral wells, and tectonically active environments or
areas where subsidence or compaction causes casing failure.
7-in. Liner Case
After analysis of the 9 5/8-in. job, there was an opportunity to
introduce a cement system that would provide much improved
zonal isolation across the gas zones to be cased by the
production liner..
Cement-Sheath Stress Modeling. The stress analysis
software was used to assess the need for a flexible, expandable
sealant system. A series of simulations were run to predict
cement-sheath behavior across the production liner using
different slurry designs including a flexible and expandable
sealant system (Fig. 3a and 3b).
The simulation was run assuming a mud-weight change
from 10.7 ppg across the liner section to 9.9 ppg in the
completion fluid. That variation would lead to a pressure
decrease of 540 psi. The slurry type used behind the liner was
the conventional system used for similar sections under the
same downhole conditions. After running the simulation, a
micro-annulus was detected across that section. The flexible,

SPE 92361

expandable sealant system proposed has the ability to prevent

micro-annulus formation. This becomes critical in gas-bearing
formations so an expansion agent was included. Coupled with
the expansion agent, the presence of flexible material
improved the internal stress distribution mechanism of the set
cement and enabled it to withstand pressure and temperature
variations throughout the perforation and testing phase.
Slurry Design. Although set-cement mechanical properties
are improved, other factors should be considered before
designing the slurry. The increase in flexibility is directly
associated with a decrease in compressive strength.2 The
slurry designed had a compressive strength of 2,750 psi
(determined from a standard crush test) compared to the
4,000-psi compressive strength of the conventional systems
used previously. Please refer to Table 1 for a summary of the
slurry properties.
Expansion. For the case under consideration, the confining
rock was given as limestone with a Youngs modulus of
4,000,000 psi. Expanding cements exhibit the best properties
against hard formations and decrease the risk of creating an
inner annulus between the casing and the cement because of
linear expansion against the unconsolidated formation. This
was demonstrated in a study by Baumgarte et al.7
The concentration of expansion additive required for a
certain value depends on several factors. These include
bottomhole static temperature (BHST), nature of the
surrounding formation, cement type, and slurry additives.
The amount of expansion can only be measured by testing
in annular-expansion molds (Fig. 4) under downhole
conditions. Baumgarte et al. describe the detailed testing
procedure.7 The expansion refers to the external volume
increase of the cement matrix. For the sample under test, after
three days of curing, linear expansion of the set cement was
2.0%. Compare this expansion to plaster (0.75%), salt cement
(0.1%), and neat cement (3% shrinkage).
Mechanical Properties. The Youngs modulus and the
Poissons ratio of the system are key parameters for a
representative stress analysis. For comparison, two tests were
done on class G neat cement and Class G cement with 35%
silica flour systems and the same slurry density. The result
was satisfactory, as demonstrated in Table 2.
Further testing in a third-party laboratory gave similar
results for the Youngs modulus and the Poissons ratio.
Mechanical-properties testing also included tests to determine
tensile strength of the set cement.The method used here is the
Brazilian Tensile Strength Test. For this test, samples of the
cement are cut to ensure flat and parallel end faces in
accordance with International Society of Rock Mechanics
(ISRM) recommended procedures. Then, the sample periphery
is wrapped with a single layer of masking tape and mounted
on the testing apparatus. Samples (approximately 1 in. in
diameter) are loaded in a 1.5-in. diameter rig. The load on the
sample is applied continuously at a constant rate until failure.
Results are summarized in Table 3.

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SPE 92361

H. El-Hassan, Mahmoud Sultan, C. Johnson, A. Belmahi, and L. Rishmani

Job Design. A Computational Fluids Dynamic Simulator8

(CFDS) was run for the 7-in. liner job. The simulation was
based on 40% excess volume in the 8-in. open hole section
and a centralization standoff of 80%. For effective mud
removal, a simulator predicted the degree of mud removal
using rheologies and weights of the fluids pumped (refer to
Fig. 5 for an output sample). With a water-based mud at 10.7ppg density, a sequence of 60 bbl of unweighted spacer, and
100 bbl of weighted spacer at 12.0 ppg was designed to be
pumped ahead of the cement slurry. This was followed by 88
bbl of the flexible, expandable sealant system.
Job Execution. The 7-in. liner job was performed per design.
A rotating liner hanger was used and rotation was stopped
only at the end of displacement to enhance mud removal
characteristics during cement placement.
Job Evaluation. The CFDS was used in post-job mode with
actual acquisition data from the job, which included pumping
rates, fluid densities, and pressures encountered throughout the
job. The simulator showed a minor discrepancy between
design pressures and actual pressures. This discrepancy and
some soft cement found on top of the liner indicated an actual
open-hole excess of 80% (having only considered 40% excess
during the design phase). From the above difference in
placement conditions, there was concern about the cementbond log result.
A cement-bond log was run on the 7-in. production liner
after drilling the 6-in. horizontal open-hole section. The mud
weight had already been decreased to 9.9 ppg. The cementbond log showed very good results with no indication of
micro-annulus formation (refer to Fig. 6 for cement bond log
section).
System Application
After successful evaluation of the flexible, expandable sealant
system, it was used as the standard system for wells with
similar conditions. To date, 15 jobs have been performed on
production casings and liners. The system is engineered for
good compressive strength, mechanical properties, and bondlog response indication, in a wide range of well objectives and
conditions.
Conclusion
This paper has demonstrated the importance of set-cement
mechanical properties in maintaining integrity of the cement
sheath.
By using a given set of downhole conditions (mainly
wellbore pressure variation), the behavior of the set cement
under stress conditions can be simulated to predict mechanical
failure and formation of micro-annuli.
Based on well-failure experience, a flexible, expandable
sealant system was chosen that exhibits increased flexibility
and a high level of expansion capability to provide the
required zonal isolation.

Acknowledgments
We thank the management of Schlumberger, ADCO, and
ADNOC for the support and the permission to publish this
paper.
Nomenclature
E = Youngs Modulus [psi]
= Poissons Ratio [dimensionless]
l = Dimensional change in-line with force [mm]
r = Dimensional change perpendicular to force [mm]
SI Metric Conversion Factors
bbl
1.5897 E-01 = m3
in.
2.540 E-02 = m
lbm
4.536 E-01 = kg
lbm/bbl 2.853 E+00 = kg/m3
lbm/gal 1.198 E+02 = kg/m3
lbm/gal 1.198 E-01 = kg/L
lbm/cuft 1.602 E+01 = kg/ m3
psi
6.894757 E+00 = kPa
References
1.

2.

3.

4.

5.

6.

7.

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Thiercelin, M. J., Dargaud, B., Baret, J. F., and Rodriguez,

W. J.: Cement Design Based on Cement Mechanical
Response, SPE 38598 presented at the SPE Annual
Technical Conference and Exhibition held in San Antonio,
Texas, Oct. 58, 1997.
Le Roy-Delage, S., Baumgarte, C., Thiercelin, M., and
Vidick, B.:New Cement Systems for Durable Zonal
Isolation, SPE 59132 presented at the IADC/SPE Drilling
Conference held in New Orleans, Louisiana, Feb. 2325,
2000.
Boukhelifa, L., Moroni, N., James, S.G., Le Roy-Delage,
S., and Thiercelin, M. J.:Evaluation of Cement Systems
for Oil and Gas Well Zonal Isolation in a Full-Scale
Annular Geometry, SPE 87195 presented at the
IADC/SPE Drilling Conference held in Dallas, Texas, Mar.
24, 2004.
Barclay, Ian S., Johnson, Carl R., Staal, Timo W.,
Choudhary, Suresh, and Al-Hamadani, Suresh: Utilizing
Innovative Flexible Sealant Technology in Rigless Plug
and Abandonment, SPE 89622 presented at the
SPE/IcoTA Coiled Tubing Conference and Exhibition held
in Houston, Texas, Mar. 2324, 2004.
Moulin, E., Revil, P. and Jain, B.: Using Concrete
Technology to Improve Performance of Lightweight
Cements, paper SPE/IADC 39276 presented at the
SPE/IADC Middle East Technology Conference, Bahrain,
2325 November 1997.
Boukhelifa, L., Moroni, N., James, S.G., Le Roy-Delage,
S., and Thiercelin, M. J.:Evaluation of Cement Systems
for Oil and Gas Well Zonal Isolation in a Full-Scale
Annular Geometry, SPE 87195 presented at the
IADC/SPE Drilling Conference held in Dallas, Texas, Mar.
24, 2004.
Baumgarte, C., Thiercelin, M., and Klaus, D.:Case Studies
of Expanding Cement to Prevent Microannular Formation,
SPE 56535 presented at the SPE Annual Technical
Conference and Exhibition held in Houston, Texas, Oct. 3
6, 1999.

Using a Flexible, Expandable Sealant System to Prevent Microannulus in a Gas Well A Case History

8.

Piot, B. M., Loizzo, M.: Reviving the Job Signature

Concept for Better Quality Cement Jobs, IADC/SPE
39350 presented at the IADC/SPE Drilling Conference held
in Dallas, Texas, March 36, 1998.

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SPE 92361

SPE 92361

H. El-Hassan, Mahmoud Sultan, C. Johnson, A. Belmahi, and L. Rishmani

Rheology after mixing

PV (cp)
Ty (lbf/100 ft2)
Rheology conditioned
PV (cp)
Ty (lbf/100 ft2)
API free water (mL)
API fluid loss (mL/30min)
Thickening Time
40 Bc (hh:min)
100 Bc (hh:min)
Compressive Strength
Crushing at 24:00 hrs (psi)
UCA at 65:00 hrs (psi)

166
35
158
24
None
28
04:45
05:00
2750
1550

TABLE 1- LINER SLURRY PROPERTIES

Slurry
Slurry 1 Flexible,
Expandable Sealant System
Slurry 2 G + Silica Blend
Slurry 3 G Neat Cement

Youngs
Modulus (psi)
900,000

Poissons
Poisson s
Ratio
0.20

1,700,000
1,500,000

0.19
0.22

TABLE 2- MECHANICAL PROPERTIES OF THREE SLURRY

SYSTEMS

Sample

Flexible
Expandable
Cement

Mean
Length
(mm)
13.21
12.96

Mean
Diameter
(mm)
25.19
25.18

Peak
Load
(N)
1340
1290

BTS
(psi)

Mean
BTS
(psi)

370
363

367

TABLE 3- BRAZILIAN TENSILE STRENGTH TEST

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Using a Flexible, Expandable Sealant System to Prevent Microannulus in a Gas Well A Case History

SPE 92361

Figure 3a- Stress analysis software input window for 9 5/8-in

pressure testing case

Figure 1- Cement evaluation log across a selected section of the 9

5/8-in casing prior to pressure testing

Figure 3b- Stress analysis software output windows for 9 5/8-in

pressure testing case

strain gauge

Figure 2- Cement evaluation log across same section of the 9 5/8in. casing after pressure testing
113 mm
195 mm

Figure 4- Annular expansion mold

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SPE 92361

H. El-Hassan, Mahmoud Sultan, C. Johnson, A. Belmahi, and L. Rishmani

Figure 6- Cement evaluation log across a selected section of the

7-in liner

Figure 5- Mud removal simulator showing optimized hole cleaning

in the 7-in. liner section

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